Letterpress application of elastomeric compositions

Abstract

The invention provides a process to deliver an elastomeric composition to a substrate. The elastomeric composition is cooled. The cooling also results in substantially complete transfer of the elastomeric composition from the pattern roll to the substrate with a resulting reduction in elastomer degradation.

What is claimed is: 
     
       1. A process of manufacturing a stretch composite, the process comprising the steps of:
 a) providing a polyolefin based substrate, wherein the substrate has a thickness between about 0.05 millimeters and about 2 millimeters; 
 b) providing a letterpress adhesive application system comprising a pattern roll and an applicator roll; 
 c) depositing a molten, non-adhesive, elastomeric composition onto the applicator roll, wherein the elastomeric composition has a viscosity that is greater than 1000 Pascals·S at a temperature of 175 degrees Celsius; 
 d) transferring only a portion of the elastomeric composition that is on the applicator roll, from the applicator roll to the pattern roll, by contacting the pattern roll with the elastomeric composition that is on the applicator roll; and 
 e) transferring substantially all of the elastomeric composition from the pattern roll to the substrate, by contacting the substrate with the elastomeric composition that is on the pattern roll, without damaging the substrate. 
 
     
     
       2. The process of  claim 1 , wherein the providing of a polyolefin based substrate comprises providing a polypropylene based substrate. 
     
     
       3. The process of  claim 1 , wherein the providing of a polyolefin based substrate comprises providing a polyethylene based substrate. 
     
     
       4. The process of  claim 1 , wherein the providing of a polyolefin based substrate comprises providing a substrate, and wherein the substrate has a thickness between about 0.1 millimeters and about 1 millimeter. 
     
     
       5. The process of  claim 1 , wherein the providing of a polyolefin based substrate comprises providing a substrate, and wherein the substrate has a thickness between about 0.1 millimeters and about 0.5 millimeters. 
     
     
       6. The process of  claim 1 , wherein:
 the transferring of only a portion of the elastomeric composition takes place at a first temperature; and 
 the transferring of substantially all of the elastomeric composition takes place at a second temperature that is less than the first temperature. 
 
     
     
       7. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is at least about 25 degrees Celsius less than the first temperature. 
     
     
       8. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is at least about 50 degrees Celsius less than the first temperature. 
     
     
       9. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is at least about 65 degrees Celsius less than the first temperature. 
     
     
       10. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is less than or equal to an order/disorder temperature of the elastomeric composition. 
     
     
       11. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is less than or equal to an order/disorder temperature of the elastomeric composition, and wherein the order/disorder temperature is at least about 180 degrees Celsius. 
     
     
       12. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is less than or equal to an order/disorder temperature of the elastomeric composition, and wherein the order/disorder temperature is at least about 150 degrees Celsius. 
     
     
       13. The process of  claim 6 , wherein the transferring of substantially all of the elastomeric composition takes place at a second temperature that is less than or equal to an order/disorder temperature of the elastomeric composition, and wherein the order/disorder temperature is at least about 140 degrees Celsius. 
     
     
       14. The process of  claim 1 , wherein the transferring of substantially all of the elastomeric composition comprises transferring at least about 90% of the elastomeric composition from the pattern roll to the substrate. 
     
     
       15. The process of  claim 1 , wherein the transferring of substantially all of the elastomeric composition comprises transferring at least about 95% of the elastomeric composition from the pattern roll to the substrate. 
     
     
       16. The process of  claim 1 , wherein the transferring of substantially all of the elastomeric composition comprises transferring at least about 99% of the elastomeric composition from the pattern roll to the substrate.